Thanks, and yes I will try all the updates that SL has made. I just wanted to start it right at Orion+ and go up.If you think about rebuild the frame then take a look at this also.
http://www.ltlewis.co.uk/b15.htm
Thanks for the panzerholz link. Not sure if mechanical strength matters quite as much in an open baffle design as in a closed cabinet, but it can't hurt and panzerholz is certainly easier to work with for the average DIYer than slabs of metal.
As for the ASP, I am tempted to say that going through the pre-3.3.1 versions is a bit of a waste of time. While earlier versions were very good, 3.3.1 is superior in several ways, and makes the Orion a truly great speaker in my opinion. (The C7+R5 mod might well be a matter of personal taste and room interaction.)
On the other hand, it is quite an interesting educational process to experience the subtle but significant improvements from the various modifications. And with your obvious level of skill, the risk of the copper tracks separating from the ASP circuit board due to repeated component re-soldering should be minimal.